My first buggy build

[Bvega]

Have not been on here in some time. I used to have a 2 seat Toyota based buggy 1 tons etc. I have decided I need a 4 seat rig to take the family out with wheeling with me. So I got rid of the old buggy and purchased a Toyota 4 runner. The 4runner came with some really good parts. The plan is to use those parts and build a new buggy. I have been wheeling for just over a year now. Since I got started into this hobby I have wanted to build something myself. I do not have alot of experience wheeling and none fabricating. So I in listed the help of my friend Josh Corso from Corso Fab. to help me out. We have been working on this project for a few months. It has been going real good. It has been a great experience so far. I have learned so much since we have started. So I thought I would start a build thread to show what we have done and where we are at now.

Specs:

Started life as a 1987 4runner

- 22RE motor

- W56 out of a '94 that was just rebuilt

- Marlin Crawler Ultimate dual cases with 4.7's in rear with NEW bobby long output

- 40" LTB

- Front D60, 4.88's, spool, 35spl inners and outers, dedenbear knuckles, warn premium hubs, Bluetorch link truss, with intergrated Diff cover and Hydro steering ram mount

- Full Hydro steering with double ended ram, grant steering wheel with quick disconnect

- Rear D70U (smooth bottom) 4.88's, welded, 35 spl. shafts, disc brake conversion, No limit fab axle truss with integrated Diff cover

- 4 link suspension Front and rear link ends are Evolution joints

- 16" SAW coilovers front

- 17" Bilstein coilovers rear

- Mastercraft suspension seats in front with Simpson harness, stock sami rear bench seat with Crow industries harnesses

- rear t-case has twin sticks

- MSD ignition system

Along with some other stuff, but you get the idea.

Here is what it looked like when I first got it.





First thing we had to do was get it striped down. Also put some 44" TSL's on for kicks. Wanted to see how they looked on it.





Cutting off the rest of the cage.




Removed the motor, tranny, and t-cases. Built a new frame, motor and case mounts

[Bvega]

Setting up front axel and front four link















Getting the rear ready for mock up



Some of the overall 112" wheel base




This is the coolest tool to have in your garage Plasma table. We have made all the tabs with this machine it spits them out quick

[Bvega]

Some more of the frame.






notch the frame to give front uppers a little more room and to help with the ride height.










Started on building the rear links. 2" DOM . 380 wall




Front and rear links done rolled it out of the garage for the first time.

[Bvega]

So here is an idea of what the buggy is going to look like when its done. Not a total match but close.





Picture of a completed rig.






The design is from AZrockcrawlers they sell drawings for this and a number of other chassis.

[Bvega]

Starting on the tube work. This is the floor of the chassis







Tube work continues









Just a idea of how it is looking

[Bvega]

Placed the chassis onto the frame.









And here is what it looks like ROLLED out of the garage. Mind you this is still ruff the rear needs to be made for the seat and gas tank. The front is missing all the engine bracing, shock location, and firewall. Then we need to gusset and build the roof. But it is starting to look like something.









I am real happy with the way its turning out. Cant wait till its done so I can go beat on it.

[Bvega]

Got the 40" LTB on

Side by side with 39.5" TSL


On the rig






my favorite



Got the rear seat and fuel cell bars in and the rear shocks mounted.









Got the front shocks mounted. Found that one of the coilovers has a bent shaft and I will need new spring rates all the way around. Going to continue with the build and then weight it. Right now we are 6'2" to top of tubing with 23" of belly clearence.

[Bvega]

Here are a few more pics








This is how it sits today. We are trying to have this POS ready for the start of the hammer season. We should be ready for the first test run in the middle to end of August

[Mike330R]

Very nice!

I'd kill to have a plasma cutter :)

Love the Jimmy in the back ground of some of the pic's!

[MAGOO]

Looks good is the chassis DOM or 4130 ?

[dezertcrawlin]

Hell yea that looks awesome.  Ton of work.  Curious how long its been start to now? 

[Bvega]

Its 1.75" .120 wall DOM

[84socal]

middle of aug   i thought u were gonna try to get it done for the midnight brawl     


oh   and id raise the whole thing so the belly about an inch  or so  higher   ull drag the belly over things     i do  and im at  24  just ask my old gas tank   

[Bvega]

That was the plan and I am still trying to make that date. But honestly I don't think it will be. I don't want to rush and I want to take it out when its complete. It is going to be close.

Belly is 23.75 right now. I think that will be high enough. Old buggy was 20" to belly. If anything I am going to lower the rig to 22".

Started the project in late Feb. Had some down time getting funds together and trying to figure out what we were doing.

[Bvega]

Forgot to add these yesterday











This is how its sits right now. I have to readjust the rear suspension. Once we get the new spring rates.

[Bvega]

Got the cross bracing in for the roof. Tube in for the boat side. Windshield bars in. Front drive shaft built. Almost ready for paint.











Still have a few inches of travel not being used. Engine hoist will only go so high


cross bracing and stuff











thats it for now more pics next week.

[hammeredtoys]

Looking bad ass bert

[Bvega]

thanks Don

We have along way to go and I have not had anytime to work on it. Hoping to get back at this weekend or next. Need to get this done by the end of Sept. Its going to be close. 

[Bvega]

Went up today to work on the rig, Spent the whole time cutting card board for the sheet metal. No pics sorry. Still trying to figure the color for this thing, I just want it done so I can wheel.

[Mikegyver1]

Metalica Green with tons of green pearl